Fabric with magnetic fibers

ABSTRACT

A magnetic article is formed from a magnetic fabric that is formed using individual magnetic fibers and is preferably held in its desired shape with stitches. The magnetic article can be used for therapeutic purposes by weaving the magnetic fibers into the magnetic fabric maintaining the magnetic article in close proximity to the user to improve its therapeutic efficacy. The magnetic fibers are preferably sheath-core fibers with a magnetic core and may alternatively be composite fibers with magnetic particles encapsulated in a polymer, giving the magnetic fabric an aesthetically pleasing drape and a tactile handle. The magnetic fibers can be made from slit films suitable for textile processing and additional processing can be used to magnetize the individual fibers. The magnetic fibers can be woven in patterns, and additional layers of magnetic material can be formed on or incorporated into the magnetic fabric using known processes for textiles. Solid magnets can also be added to the magnetic fabric.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0001] Not Applicable.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] Not Applicable.

BACKGROUND OF THE INVENTION

[0003] 1. Field of the Invention

[0004] This invention relates generally to a fabric and, moreparticularly, to a magnetic fabric formed with individual magneticfibers.

[0005] 2. Description of Related Art

[0006] According to the inventions described in U.S. Pat. Nos. 2,37,939,3,921,620, 4,162,672 and 6,093,143, it is well known to attach discretemagnets to fabrics that are worn by a person as apparel or draped overthe person for therapeutic purposes. Such magnets are not integral withthe fibers that are woven into the fabric or with the fabric sheet.Instead, the fibers are manufactured in a process distinctly separatefrom the manufacture of the magnets, and the magnets must therefore beseparately attached to the fabric at particular locations. The magnetsmay be small enough to be embedded into a sheet of synthetic material,but such embedding magnets are not applied to the individual fibers andinstead applied after weaving the fibers into the fabric.

[0007] Similarly, according to the respective inventions described inU.S. Pat. Nos. 4,549,532 and 5,882,292, it is also known to embedmagnetic material into a sheet and to layer a magnetic material onto afabric. The magnetic layer may be integral to such a layered magneticfabric and the sheet, but the layer is not integral to individual fibersthat form the fabric. To form the magnetic fabric, first thenon-magnetic fabric must be formed using traditional weaving processes,and then the magnetic layer can be applied thereto.

[0008] Finally, according to the invention described in U.S. Pat. No.4,515,850, it is known to surround a core fiber with a sheath ofmagnetic material and that such core-sheath fibers can be woven into aferrite cloth for electronic equipment. Even though the electronicequipment may include electromagnetic shields and permanent magnets, thepurpose of such ferrite cloths is for the manufacture of electronicequipment and such ferrite cloths are not intended to be worn by orcover a person. A core-sheath fiber with a composite ferrite cover maybe acceptable for electronic equipment, but it would not provide thelook and feel that a person would expect from traditional textilefabrics. Additionally, multiple ferrite cloths must be laminatedtogether for practical use in electronic equipment, whereas no suchlamination is generally required for fabrics that are worn by orotherwise cover a person.

BRIEF SUMMARY OF THE INVENTION

[0009] It is in view of the above problems that the present inventionwas developed. The invention is an article of magnetic fabric formedfrom individual magnetic fibers and preferably held in a desired shapewith stitches. The magnetic fibers are preferably sheath-core fiberswith a magnetic core and a traditional textile sheath. In an alternativeembodiment, the magnetic fibers are a composite of magnetic particlesencapsulated in a polymer. The fabric can be formed using traditionalconstruction methods, including weaving, knitting, and nonwovenprocesses. The magnetic fabric has an aesthetically pleasing drape and atactile handle. The magnetic fibers can be made using a slit filmprocess suitable for textiles, and the magnetic fibers can be woven inpatterns. Additional layers of magnetic material can be formed on orincorporated into the magnetic fabric using known processes fortextiles, including finishing, coating, and printing processes, andsolid magnets can also be added to the magnetic fabric using knowntechniques.

[0010] Accordingly, it is one advantage of the present invention toprovide magnetic fibers that can be woven into a fabric. It is anotheradvantage of the present invention to provide a magnetic core-weavefabric that has therapeutic efficacy and also has a look and feel thatis substantially similar to traditional textile fabrics. It is yetanother advantage of the present invention to provide a magnetic fabricthat can be further processed to incorporate additional magneticproperties into the magnetic fabric. It is yet another advantage of thepresent invention to provide a method for using a plurality of magneticfibers for therapeutic purposes.

[0011] Further features and advantages of the present invention, as wellas the structure and operation of various embodiments of the presentinvention, are described in detail below with reference to theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The accompanying drawings, which are incorporated in and form apart of the specification, illustrate the embodiments of the presentinvention and together with the description, serve to explain theprinciples of the invention. In the drawings:

[0013]FIG. 1 illustrates a magnified, perspective view of an article ofmagnetic fabric according to the present invention;

[0014]FIG. 2 illustrates a cross-sectional view of a magneticsheath-core fiber preferably used in the present invention;

[0015]FIG. 3 illustrates a cross-sectional view of an alternativeembodiment of a composite magnetic fiber used in the present invention;and

[0016]FIG. 4 illustrates several optional design features according tothe present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0017] Referring to the accompanying drawings in which like referencenumbers indicate like elements, FIG. 1 illustrates a detailed view of amagnetic article 10 that is formed from a magnetic fabric 12 andpreferably has a plurality of stitches 14 for holding the fabric 12 inits desired shape. In the preferred embodiment, the magnetic fabric 12is woven from a plurality of individual magnetic fibers 16. The magneticarticle 10 can also be formed from a magnetic fabric 12 that isconstructed using other traditional techniques for fabrics, such asknitting and nonwoven processes.

[0018] The magnetic article 10 can be used to cover or otherwise adorn auser thereof. For example, a magnetic article 10 could include clothing,fabric-type jewelry, towels and linens, and therapeutic devices. Each ofthese magnetic articles 10 can be made from the magnetic fabric 12 andhas a similar function in that it remains in close proximity to the userduring its usage. Although the preferred user would be a person, it isconceivable that magnetic article 10 could be used for pets, livestock,and other animals and beasts of burden, and it is within the realm ofpossibility that such a magnetic article 10 could be designed accordingto the present invention for certain plants. Therefore, the applicationof the magnetic article 10 may influence the design or the desired shapeof the magnetic fabric 12.

[0019] The magnetic fibers 16 can be formed from a slit film processthat is suitable for textile processing. Fibers formed from a slit filmprocess, slit film fibers, are typically flat and are traditionallyproduced by slitting an extruded polymeric film. The polymeric film isextruded and then slit into multiple strands before being drawn into thefibers. The slit film fibers may also undergo an additional heating anddrawing process to produce fibrils in the fiber's longitudinaldirection, giving the fibers a lattice-work appearance.

[0020] As respectively illustrated in FIGS. 2 and 3, the magnetic fibers16 can be a sheath core fiber 18 or another form of magnetic compositefiber 20. The sheath-core fiber 18 has a magnetic core 22 that issurrounded by a textile sheath 24. The magnetic core 22 and the magneticcomposite fiber 20 can be formed by encapsulating magnetic particles 26within a polymer fiber matrix 28. Alternatively, the magnetic core 22and the composite magnetic fiber 20 may be formed using known textileprocessing methods, such as coating the surfaces 30, 32 of the magneticcore 22 and the fiber matrix 28 with magnetic particles 26 or printingmagnetic particles 26 thereon or otherwise adhering magnetic particles26 thereto. The magnetic particles 26 may also be embedded into thesurfaces 30, 32, or the magnetic core 22 and the fiber matrix 28 can befinished or otherwise formed with magnetic particles 26. For thecore-sheath fiber 18, the magnetic core 22 may also be a thin magneticwire.

[0021] The magnetic fabric 12 is woven from fibers that use traditionaltextile materials in combination with magnetic particles 26 to give themagnetic fabric 12 an aesthetically pleasing drape and a tactile handle.Accordingly, each of the magnetic fibers 16 can be individually formedusing polymers or natural fibers in combination with magnetic particles26. Polymeric fibers can be made using regenerated cellulose andsynthetic polymers, such as polyester, polyamide and other man-madepolymers. Natural fibers may include silk, wool, mohair, cotton, hemp,flax, jute, and ramie. For the core-sheath fiber 18, the textile sheath24 may include magnetic particles 26 or may be free from any magneticparticles 26. Therefore, the look and feel of the magnetic fabric 12 canbe made substantially similar to the look and feel of traditionalnon-magnetic fabric articles, and the magnetic fabric 12 does notsubstantially limit the desired shape of the magnetic article 10.

[0022] As one example of the present invention for magnetic article 10,FIG. 4 illustrates several optional design features that can be used forclothing, fabric-type jewelry, towels and linens, and therapeuticdevices. The magnetic fibers 16 can be woven into the magnetic fabric 12in a pattern 34. After the fibers 16 are woven into the magnetic fabric12, a layer of magnetic material 36 can be formed on or integrally withthe magnetic fabric 12 and any number of solid magnets 38 can beattached to the magnetic fabric 12. The solid magnets 38 can be attachedto the magnetic fabric 12 alternatively to the layer 36 or incombination therewith. To attach another magnetic fabric layer 40 to themagnetic fabric 12, a plurality of stitches 42 can be used. Theaesthetically pleasing drape and tactile handle are still maintainedwhen multiple layers of magnetic fabric 12, 40 are used because thelayers of magnetic fabric 12, 40 are not laminated together for themagnetic article 10. The magnetic fabric layer 40 may also cover otheroptional design features, such as the layer of magnetic material 36and/or the solid magnet 38. In the particular example, the magneticarticle 10 is covering a person 44.

[0023] It will be appreciated that the entire magnetic article 10 can beformed from magnetic fabric 12 that is free of these optional designfeatures. In such a case, the magnetic article 10 can be made with asubstantially uniform magnetic field distribution. The magnetic fielddistribution can be modified by using magnetic fibers 16 with varyinglevels of magnetism to form different patterns 34 in the magnetic fabric12. Additionally, the optional design features can be used toconcentrate the magnetic field at particular locations, and the overalldesign can be incorporated into the desired shape of the magneticarticle 10. Concentrating the magnetic field is particularly beneficialfor making a magnetic article 10 for therapeutic purposes. Accordingly,depending on its preferred design, the magnetic article 10 can have aneven distribution of magnetic fields over its entire surface and canhave regions of varying magnetic field strength, including some regionswith very little or no magnetic properties 46.

[0024] Accordingly, based on the description above and the relateddrawings, the present invention includes a method for using the magneticfibers 16 to make a magnetic article 10 for therapeutic purposes. Themagnetic fibers 16 are woven into the magnetic fabric 12. The magneticfabric 12 is preferably sewn to hold the desired shape for the magneticarticle 10 that is held in close proximity to the body of a user 44.Before weaving the fabric 12, the individual magnetic fibers 16 can beformed using any of the methods set forth above. It will be appreciatedthat the magnetic fabric 12 can also be formed by knitting and nonwovenprocesses.

[0025] The magnetic fibers 16 can be woven in a pattern 34, and thefabric 12 can be cut into multiple shapes that form portions of thedesired shape for the magnetic article 10. For example, clothing andother apparel designs usually have a desired shape that is formed bysewing together several sections such that there are stitches 14 betweenthe various sections, such as sewing a shirt together (not shown) withsleeves, a body, and a collar. Similarly, for a therapeutic device, suchas a back brace (not shown), suspenders may also be sewn to the backbrace and the raw edges of the back brace fabric may be sewn into a hem.For bed linens, it is also common practice to sew a hem into the edgesof the fabric. For each of these applications for the magnetic fabric12, the magnetic article 10 is maintained in close proximity to a bodyof a user to improve the therapeutic efficacy. Accordingly, the user maywear or even lie on or under the magnetic article 10.

[0026] After weaving the magnetic fabric 12, standard textile processingcan be used to coat the magnetic fabric 12 with the layer of magneticmaterial 36 or to print the layer of magnetic material 36 onto themagnetic fabric 12 or otherwise adhering magnetic particles 26 thereto.The magnetic fabric 12 can also undergo a finishing process in which thelayer of magnetic material 36 may be integrally formed therewith. Thesolid magnet 38 can also be attached to the magnetic fabric 12.Additionally, the magnetic fabric layer 40 can be sewn to the magneticfabric 12, and magnetic particles 26 maybe embedded into the magneticfabric 12.

[0027] In view of the foregoing, it will be seen that the severaladvantages of the invention are achieved and attained. The embodimentswere chosen and described in order to best explain the principles of theinvention and its practical application to thereby enable others skilledin the art to best utilize the invention in various embodiments and withvarious modifications as are suited to the particular use contemplated.

[0028] As various modifications could be made in the constructions andmethods herein described and illustrated without departing from thescope of the invention, it is intended that all matter contained in theforegoing description or shown in the accompanying drawings shall beinterpreted as illustrative rather than limiting. For example, themagnetic fibers 16 can be woven into patterns 34 that have shapes otherthan those particularly illustrated, and these shapes may besignificantly different for according to the type of magnetic article10, including its preferred design and desired shape. Thus, the breadthand scope of the present invention should not be limited by any of theabove-described exemplary embodiments, but should be defined only inaccordance with the following claims appended hereto and theirequivalents.

What is claimed is:
 1. A magnetic article having a desired shape,comprising: a magnetic fabric, wherein said magnetic fabric is furthercomprised of a plurality of magnetic fibers; and a plurality of stitchesholding said magnetic fabric in the desired shape of the magneticarticle.
 2. A magnetic article according to claim 1, wherein saidmagnetic fibers are formed from slit film fibers suitable for textileprocessing.
 3. A magnetic article according to claim 1, wherein saidmagnetic fibers are sheath-core fibers and each of said sheath-corefibers further comprises a magnetic core fiber and a textile sheathsurrounding said magnetic core fiber.
 4. A magnetic article according toclaim 1, wherein said magnetic fibers are composite fibers and each ofsaid composite fibers further comprises magnetic particles encapsulatedby a polymer.
 5. A magnetic article according to claim 1, wherein themagnetic article has an aesthetically pleasing drape and a tactilehandle.
 6. A magnetic article according to claim 1, wherein saidplurality of magnetic fibers are woven into said fabric in a pattern. 7.A magnetic article according to claim 1, further comprising a layer ofmagnetic material coated onto said magnetic fabric.
 8. A magneticarticle according to claim 1, further comprising a layer of magneticmaterial printed onto said magnetic fabric.
 9. A magnetic articleaccording to claim 1, further comprising incorporation of magneticmaterial into said magnetic fabric through textile finishing techniques.10. A magnetic article according to claim 1, further comprising a solidmagnet attached to the magnetic fabric.
 11. A sheath-core fiber formagnetic fabrics, comprising: a magnetic core fiber; and a textilesheath surrounding said magnetic core fiber.
 12. A sheath-core fiberaccording to claim 11, wherein said magnetic core fiber furthercomprises magnetic particles encapsulated by a polymer.
 13. Asheath-core fiber according to claim 11, wherein said magnetic corefiber further comprises magnetic particles combined with a naturalfiber.
 14. A sheath-core fiber according to claim 11, wherein saidtextile sheath is a polymer.
 15. A sheath-core fiber according to claim11, wherein said textile sheath is natural fiber.
 16. A sheath-corefiber according to claim 11, wherein said textile sheath is combinedwith magnetic particles.
 17. A sheath-core fiber according to claim 11,wherein said textile sheath is substantially free of magnetic particles.18. A method for using a magnetic article for therapeutic purposes,comprising the steps of: forming a magnetic fabric from a plurality ofmagnetic fibers; and maintaining said magnetic fabric in close proximityto a body of a user.
 19. A method according to claim 18, wherein saidforming step further comprises weaving the plurality of magnetic fibers.20. A method according to claim 18, wherein said forming step furthercomprises knitting the plurality of magnetic fibers.
 21. A methodaccording to claim 18, further comprising the step of cutting saidmagnetic fabric into a plurality of shapes that form at least a part ofa desired shape.
 22. A method according to claim 18, further comprisingthe step of sewing said magnetic fabric to hold a desired shape for themagnetic article.
 23. A method according to claim 18, further comprisingthe step of wearing said magnetic article.
 24. A method according toclaim 18, further comprising the step of laying on said magneticarticle.
 25. A method according to claim 18, further comprising the stepof coating said magnetic fabric with a layer of magnetic material.
 26. Amethod according to claim 18, further comprising the step of printing alayer of magnetic material onto said magnetic fabric.
 27. A methodaccording to claim 18, further comprising the step of finishing saidmagnetic fabric with an integral layer of magnetic material.
 28. Amethod according to claim 18, further comprising the step of attaching asolid magnet to said magnetic fabric.
 29. A method according to claim18, further comprising the step of sewing a magnetic fabric layer tosaid magnetic fabric.